Manual Programming of a UPS System{4480, 7620} Caterpillar

Uninterruptible Power Supply:

ES12F (S/N: CZE1-UP)

UPS 120 (S/N: CNK1-UP)

UPS 150 (S/N: CPC1-UP)

UPS 250 (S/N: CNM1-UP; APZ1-UP)

UPS 300 (S/N: CNJ1-UP; CPZ1-UP)

UPS 301 (S/N: CSY1-UP)

UPS 500 (S/N: CSE1-UP)

UPS 600 (S/N: CTX1-UP)

UPS 750 (S/N: CPM1-UP)

UPS 900 (S/N: CRY1-UP)

UPS 1000S (S/N: CZS1-UP)

UPS 1200S (S/N: CZT1-UP)

Introduction

This Special Instruction addresses the procedure for manually programming a UPS system. Refer to ""Procedure" " in order to perform an update to the existing firmware with the following revisions:

• UPS 3.30

• UPS 3.31

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use. You should ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures.

Procedure

1. Determine the date of bearing installation for your UPS system.

   During this update for firmware and during future updates, you will be required to enter the "Bearing Install Date". If you do not know the correct date of bearing installation, contact Activepower with one of the following methods:

   • 1-800-288-5081

   • "apservice@activepower.com"

2. Ensure that your laptop computer has the current UPSView software. The current software is version 2.7.

3. Ensure that you have downloaded the appropriate electronic update for the firmware version from SISWeb to the following areas:
   • Laptop computer

   • Device for storing media

4. Place the keyswitch for the UPS system in the Bypass position.

   Note: If the UPS is a multiple module unit (MMU), place the keyswitch for the system in the Bypass position.

5. If the single-module system (SMS) is equipped with a maintenance bypass, place the system in maintenance bypass.

6. For a single-module system, connect the laptop computer to the RS-232 connector that is located on the system I/O board.

   Note: For a MMU system, connect the laptop computer to the RS-232 connector that is located on the board for the Parallel Cabinet Interface (PCI).

7. For a MMU system, select "MMU #1" via the rotary switch (PCI).

   Note: You will need to index the rotary switch (PCI) to the next sequential number for the MMU in the system in order to perform the update of firmware for that specific MMU cabinet.

8. Start UPSView and establish communication.

9. Select "Enter Password".

10. Type the appropriate username. Type the appropriate password.

11. Click "OK".

12. Perform an "ALT <Z>" on your laptop computer. Write down all of the operating parameters that are not default parameters.

13. Click on the "UPS Settings Menu" and select "Update UPS Firmware".

    If you are updating a single-module system, proceed to Step 20.

14. For a multiple module system (MMS), select the file for the firmware "PCC FPGA Firmware" from the pull-down menu.

    Note: The "PCC FPGA Firmware" file may also be indicated as "Serial Flash PCC FPGA" for versions of firmware that are older than version 2.4.

15. Click on the "Browse" button.

16. Locate the appropriate file for firmware in order to match the name of the file that was selected in Step 14. Refer to Table 2.
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    Table 1

    Single-Module System
    	Filename	Programmable Target	Affected Board
    "Boot Monitor"	apc1_bootV402_6806009_02.mot	"Byte-wide Flash PowerPC" or "Boot Monitor"	APC
    "Application"	SMS_APC1_CMP_APP_V331_6806037_04.mot	"PowerPC Application"	APC
    "Internal Flash"	SMS_MMS_APC1_INT_V143_6806038_02.mot	"Internal PowerPC Application"	APC
    "APC FPGA"	sms_mms_apc1_fpga_V120_6806039_02.ttf	"APC FPGA Firmware"	APC
    "ZZC"	zzc_102.ttf	"ZZC FPGA Firmware"	ZZC

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    Table 2

    Multiple Module System
    	Filename	Programmable Target	Affected Board
    "Boot Monitor"	apc1_bootV402_6806009_02.mot	"Byte-wide Flash PowerPC" or "Boot Monitor"	APC
    "Application"	MMS_APC1_CMP_APP_V3306806040_04.mot	"PowerPC Application"	APC
    "Internal Flash"	SMS_MMS_APC1_INT_V143_6806038_02.mot	"Internal PowerPC Application"	APC
    "APC FPGA"	sms_mms_apc1_fpga_V120_6806039_02.ttf	"APC FPGA Firmware"	APC
    "ZZC"	zzc_102.ttf	"ZZC FPGA Firmware"	ZZC
    "PCC"	ppc_110.ttf	"PCC FPGA Firmware"	PCC

17. Click on the "Program" button.

    The "Download Firmware Progress Display" will begin to increment and the display will indicate the status level of completion of the downloaded file. The "Download Firmware Progress Display" will indicate the firmware that was updated with no errors.

18. If an error occurred, document the error message. Then, retry the update of the file of firmware.

19. Click the "Reload Device" button in order to boot the "PCC" file of firmware.

20. If you have a UPS system that is three-wire, proceed to Step 26.

    For a UPS with circuitry in a four-wire option, select the file of firmware "ZZC FPGA Firmware" from the pull-down menu.

    Note: The "ZCC FPGA Firmware" file may also be indicated as "Serial Flash PCC FPGA" for versions of firmware that are older than version 2.4.

21. Click on the "Browse" button.

22. Locate the appropriate file for firmware in order to match the name of the file that was selected in Step 20. Refer to Table 1 and Table 2.

23. Click on the "Program" button.

    The "Download Firmware Progress Display" will begin to increment and the display will indicate the status level of completion of the downloaded file. The "Download Firmware Progress Display" will indicate the firmware that was updated with no errors.

24. If an error occurred, document the error message. Then, retry the update of the file of firmware.

25. Click the "Reload Device" button in order to boot the "ZZC" file of firmware.

26. Select the file "Byte-wide Flash Power PC" from the pull-down menu.

    Note: The "Byte-wide Flash Power PC" file may also be indicated as "Boot Monitor" for versions of firmware that are older than version 2.4.

27. Click on the "Browse" button.

28. Locate the appropriate file for firmware in order to match the name of the file that was selected in Step 26. Refer to Table 1 and Table 2.

29. Click on the "Program" button.

    The "Download Firmware Progress Display" will begin to increment and the display will indicate the status level of completion of the downloaded file. The "Download Firmware Progress Display" will indicate the firmware that was updated with no errors.

30. If an error occurred, document the error message. Then, retry the update of the file of firmware.

31. Click the "Reload Device" button in order to boot the "Byte-wide Flash Power PC" file of firmware.

32. When the main window for UPSView is open, press "Ctrl <I>" on your laptop computer when you see the text message "Pausing for Operator Input".

    If you perform this step correctly, the text window will display "Idled". If this step is not performed correctly, you will need to repeat this step until you have received an "Idled" statement of condition in the text window.

33. Select the file "Power PC" from the pull-down menu.

34. Click on the "Browse" button.

35. Locate the appropriate file for firmware in order to match the name of the file that was selected in Step 33. Refer to Table 1 and Table 2.

36. Click on the "Program" button.

    The "Download Firmware Progress Display" will begin to increment and the display will indicate the status level of completion of the downloaded file. The "Download Firmware Progress Display" will indicate the firmware that was updated with no errors.

37. If an error occurred, document the error message. Then, retry the update of the file of firmware.

38. Select the file "Internal Flash" from the pull-down menu.

39. Click on the "Browse" button.

40. Locate the appropriate file for firmware in order to match the name of the file that was selected in Step 38. Refer to Table 1 and Table 2.

41. Click on the "Program" button.

    The "Download Firmware Progress Display" will begin to increment and the display will indicate the status level of completion of the downloaded file. The "Download Firmware Progress Display" will indicate the firmware that was updated with no errors.

42. If an error occurred, document the error message. Then, retry the update of the file of firmware.

43. Select the file "Internal PowerPC Firmware" from the pull-down menu.

44. Click on the "Browse" button.

45. Locate the appropriate file for firmware in order to match the name of the file that was selected in Step 43. Refer to Table 1 and Table 2.

46. Click on the "Program" button.

    The "Download Firmware Progress Display" will begin to increment and the display will indicate the status level of completion of the downloaded file. The "Download Firmware Progress Display" will indicate the firmware that was updated with no errors.

47. If an error occurred, document the error message. Then, retry the update of the file of firmware.

48. Click the "Reload Device" button in order to boot the following files of firmware:
    • "Power PC Application"

    • "Internal Power PC"

    • "APC FPGA Firmware"

49. For a single-module system (SMS), the procedure is complete.

    Note: For a multiple module system (MMS), you will need to index the rotary switch (PCI) to the next sequential number for the MMU in the system in order to perform the update of firmware for that specific MMU cabinet. When all of the multiple module units have been updated, the procedure for updating the firmware is complete.

    Note: Performing an update to the "PCC" file or the "ZZC" files of firmware is not necessary. The updates for firmware for the "PCC" file or the "ZZC" files only need to be performed for "MMU1".

50. Perform a "CTRL <R>" on your laptop computer. Select the answer "Y" in order to confirm the request for operation.

51. Press "Exit".

52. Utilize the UPSView version 2.7 software and monitor the boot process.

    If there are any "Bad Value" statements, the UPS system will identify the statements by providing a yellow text message. The yellow text message will indicate the reason for the notification.

53. All "Bad Value" statements must be acknowledged and all "Bad Value" statements must be cleared. Write down the "Bad Value" statements.

54. Access the appropriate menu for the operating parameter while you are using UPSView 2.7.

    When you select the Operating Parameter, a new window will appear. You will be prompted for a new value. The default value that is displayed is the new value.

55. In order to correct a displayed "Bad Value" statement, locate the appropriate menu for the operating parameter.

    If you cannot locate the appropriate menu for the operating parameter, the operating parameter may be outside of your password authorization. In this event, you can set the default value to all the restricted parameters by selecting the "Command" menu. From the "Command" menu, click on the line that reads "Load Restricted Default Params to Flash". This will set all of the restricted parameters to the default value.

56. Enter the "ALT <Z>" Operating Parameters that were obtained in Step 12. Compare the parameters and correct any differences.

57. After updating your "ALT <Z>" Operating Parameters, perform an "ALT <Z>" on your laptop computer. Ensure that the Operating Parameters have been set. Confirm that the new "ALT <Z>" listing is the same value that was obtained in Step 12.

    The update for firmware has now been completed.

58. Perform a "CTRL <N>" on your laptop computer. Confirm that the "Revision History" report matches Table 1 and Table 2.

    A new user command of "Set Bearing Install Date" has been added. The command sets the operating parameters for the "bearing install date" to the current date that has been entered. Use this command for the following actions:

    • Start-up mode

    • Installation of new service replacement bearings

    The "Bearing Install Date" parameter consists of the following sequence: Year, Month and Day.

59. Enter the new date for the bearing installation. Refer to Step 1.

    Note: The firmware for UPS will not accept an incorrect date for the bearing installation. A red text message will appear in UPSView that states "Invalid Bearing Install Date".